Mechanism for manufacturing hollow blocks



yG. A..'BUTTRESS MECHANSM FOR MANUFACTURING HOLJGW BLOCKS F'lled Feb 26 1924 3 Sheets-Sheet 1 Nov. 30 1926.

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Nov. 3o A, 192.6.

y1,608,768 G. A. BUTTREss MECHANISM FOR MANUFACTURING HOLLOW BLOCKS Filed Feb. 26, 1924 3 Sheets-Sheet 2 Nov. "30 1926.

1,608,768 G. A. BUTTR'ESS MECHANISM FQR MANUFACTURING HoLLow BLOCKS Filed Feb. 26. 1924 3 sheets-sheet a (Forge/1 Buzfre s s Patented Nov. 30, 1925.

UNITED STATE GEORGE A. isT Tr'rnnss7V or Los ANGELES,

CALIFORNIA, ASSIGNOR T0 BUTTRESS GYP- suivr TILE COMPA'Y, or Los ANGELES, crimson-SNIA, n conronnfron or GALI- FORMIA.

MiicHAN'rsM ron MANUFACTURING HOLLOW BLOCKS.

.application filed ree-mary 2e, isa-i. sei-iai Nb, eegis's This invention relates to the manufact-ure of hollow blocks, formed of plastic material and particularly pertains to al machine and to parts and features thereof, for forming blocks from a composition oi pla-.ster of Paris' which blocks are especially adapted for use inthe erection of the interior walls or partitions in building construction.

An object oi' this invention is to provide a mechanism whereby hollow blocks may be iforrned of a plastic material wilt-h accuracy and rapidity and withl a negligible waste of material whereby the blocks may be economically produced in large quantities.

Another object is to provide a' block forming machine which operates in such manner as to mold the bloclrs separately andv eject them' in finished torni, and which embodies a series or molds carried by an endless conveyor adaptedto be maintained continuously in motion' during operation of the machine, and which so coacts with other elements that the blocks will be formed and ejected with out stop and' start, or intermittent or delayed movementof the conveyor, thereby enabling great rapidity or output or the machine.

Another object is `to provide a block molding machine in which a gang of molds will bee-employed, and each mold adapted to form a plurality oi blocks at thev same time,` and in which the blocks will be ejected successively trom the molds. l

Another object isto provide a block mold-` ing machine which is particularly adapted to moldl blocks from a quick setting plastic composition.

With the 'foregoing objectsv in view, together with such other objects and advaiitages may subsequently appear, my invention resides in the parts, and in the con-A struction, combination and arrangements or parts or theirequivalents. and in the` steps and.` features hereinafter described' and claimed and ilflns'trated by way or example in the accompanying drawings,- i-n which- Figure l is a diagram in perspective illustrating a torni oi the mechanism employed in carrying outl the inventionu Fig-ure 2 is a perspective view illustrating a hollow block constituting the product oi' the mechanism shown in Figure l.

Figure 3 is a detail in cross section as Seen on the line rdf-3 ci Figure 2.

Figurel is afra'gnientary perspective view as .seen atthe point indicated by the numeral fl in Figure l,- illustrating" the manner of lubricating'the mold? box.

Figure 5l is' an enlarged detail in section as' seen on the line 5 5 oi' Figure l, showing the manner of feeding plastic composition to tlie inol'dy box.

Figure 6 is a perspective View of the mold box. e

Figure is a view or the mold boxA as seen in vertical section and elevation.`

Figure 8 is a view in horizontal sectionA or' the mold box as seen on the line 8-8 of Figure 7,-illu'strat'iiig`the manner of hingedly connecting adjacent mold boxes together for relative articulate movement.l

Figures 9 and l0 are views in vertical section illustrating the manner of ejecting the blocks from the molds Figure ll is a vieurr in elevation, partly in section, showing the manner" or restoring the molds to a norinlal position after ejection of the" blocls4 therefrom, and illustrati-ng the manner ot lubricating the mold boxes.

Figure l2 is a: view in end elevation as indicated by the arrow l2" in Figure 1l.`

Figure I3 is a. detail in perspective illus tra-ting the' manner orconstructing and operating the false bottom employed' in the molds. My invention contemplates the manui'ac ture of hollow block A having a body' B of' rectangular form, the body being' formed with a plurality of openings C eXtending nearly' therethrough from one edge thereof, as shown i'n Figure 3; the openings C being preferably `substantia-lly cylindrical. The blocks are mollcled of a suitable plastic 1na terialprel'erably consisting of it quick set#A tingl plaster i'orined oi gypsum or plast-ferl of Paris mixed with water and' containing sawdust or other suitable fibrous material fornr ing a ill'er and1 binder, as is commonly employed inthe construction or building bloclt's or thischar'acter. The ingredients or the plastic composition are prepared in a suitable mifxer indicated at D in Figure l and are autonia'tically delivered at station' E to a series oliiiold boxes F arranged in the" form or" an endless conveyor G which conveyor is mounted andA arranged `to carry the mold boxes on a horizontal plath of travel with a continuous movement during operation; the plastic composition being delivered to the mold boxes while the latter are in motion. rlhe conveyor G is ot such length and rotates at such speed that the wet unstable plastic composition delivered to the mold box at station E will have time to set and harden sufficiently to permit their removal 'from the mold boxes when the latter reach a discharge station H where the blocks are ejected from the mold boxes while the latter are advancing. rllhe blocks are then removed while moist from the mold conveyor and placed upon an endless belt l upon which they are carried and advanced for such length of time as to permit the molded blocks to harden suiliciently to permit their being stacked in superposed relation, whereupon the blocks are removed from the conveyor l and arranged in a staclr J on a car or carriage, and are then conveyed to a suitable kiln, not shown, where they are subjected'to a nal drying action; the car carrying the blocks being disposed in the kiln during the drying operation. The blocks may be arranged on the conveyor l and in the staclr J' in any desired posit-ion and by any suitable means, being here shown as arranged on edge. The transt'er of the blocks from the mold conveyor G to the endless conveyor land from the conveyor l to the stack J may be effected manually.

The mold conveyor G is of such length and is run with such speed that the mold boxes will travel about ten minutes between the stations l) and H, and the endless conveyor l is ot such length and moves at such speed that a block may be carried 'forward thereon tor about ten minutes.

The mixer D is here shown as comprising a horizontally extending cylinder 15 to which a mixture of fibrous and cementitious materials is delivered from a pair of hoppers 16 and 17 through a feed pipe 18. rlhe cementitious material in dry powdered form is delivered to the hopper 16 by a conveyor 19,` and the brous material consisting of sawdust or the equivalent thereorp being de* livered to the hopper 17 by the conveyor 20; the co-nveyors 19 and 2O leading from suitable reservoirs of the dry materials. The hoppers 16 and 17 open to cylinders 21 and 22 which communicate with branch pipes 23 leading to the common feed pipe 18; the hoppers beingv itted with agitators 24 by which the materials delivered thereto are actedon to reduce lumps and insure their delivery to the cylinder 15 in a powdered form. rlhe cylinders 21 and 22 are litted with screw conveyors 25 which serve to insure a uniform discharge of the materials to the cylinder 15. The screw conveyors 25 are driven through change speed pulleys 26 which are adapted to be adjusted to vary the speed ot the screw conveyors so as to enable the delivery to the cylinder 15 ot the cementitious and fibrous materials in any desired propormoat/es tions, as occasion may require. The cylinder 15 is fitted with an agitator 27 consisting ot blades 28 mounted on a shaft 28 extending longitudinally through thev cylinder,

which shattis adapted to be rotated so as to cause the blades to agitate the material delivered to the cylinder and also elfect their rapid advance longitudinally thereof, from the feed pipe 16 located adjacent one end of the cylinder lto a discharge pipe 29 located adjacent the other end thereof, and which discharge pipe leads downwardly and terminates in a rectangular nozzle 30 which opens directly above a mold box F in the mold conveyor G. A water feed pipe 31 connects with the cylinder 15 at a suitable point between the intake pipe 18 and discharge pipe 29 through which water is supplied to the cementitious and brous materials in the cylinder and is thoroughly intermixed therewith by the agitators 27 to 'form a. wet unstable plastic mass which will be discharged to the mold boxes through the nozzle 30,

The mold conveyor G comprises a series of fre irrnber or' hingedly connected mold boxes F rranged in an endless chain which aasses around horizontal sprocket wheels 32 and 33 carried on the upper end portions ot ical shafts and 35, litted with worin wheels 36 and 317 engaged by worms 38 and 39 on a drive shaft 40. This drive shatt may be driven from any suitable source of power. rlfhe mold conveyor G is supported on inner and outer endless rails d1 and ll2 which are here shown as formed ot channel iron ar ranged alongside the mold boxes with their channels opening towards the end walls thereoit to receive ant carry rollers 43 and a carried on the ends the mold box-es as will be later described.

Each ot the mold boxes, F is constructed as particularly shown in Figures 6, 7 and 8 (Sheet 2), and comprises side walls l5 and 46 and end walls li-7 and 48, which walls term a rectangular structure which is open at top and bot-tom and is divided into a series of compartments here shown as four in number, and indicated at a, Z), ct1 and d, by partitions 49.. The upper edges Vot' the side and end walls extend on a plane and are bounded by horizontal marginal flange 50, and the upper edges ot the parti tions 4Q extend tlush with the upper edges ot the side and end walls. i series ot trans-- verse bars 51 extend between the side walls 45 and through notches 52 termed in the lower edges ot the partitions 49, and carried on the bars 51 are upwardly projecting cylinders 53 constituting cores, there being a series of such cylinders arranged in eac i ot the compartments a, o, o, Z and spaced apart therein7 and 'from the sides and ends lot the compartnients, so as to lform a mold space around each core. |lihe upper ends lill) .of the cylinders 53 are closed and terminate on a plane spaced a' short distance below theplane or the upper edges of the walls and partitions. The end wall 47 carries a frame 54 litted with spindles 55 which project outwardly therefrom and form bearings for the rollers 44 that travel on the outer rail 42.,A Thek inner end wall 48 carries av plate 56 from which project spindles 57 forming bearings for the rollers 43 which travelon the inner rail 41. The ends or the plates. 56 project beyond the plane ot the side walls 45 and 46 and are formed with apertured bosses 58 to receive pivot ins 59, by means of which adjacent mold boxes are hingedly connected together so as to have articulate movement relative to each other and form an endless chain to pass around the sprocket wheels 32 and 33; the sprocket wheels being formed with peripheral recesses 60 adaptedto engage projectingupper end portions 61 of the pivot pins 59 so as tofetfect a sprocketconnection with the endles chain or mold boxes and effect movement thereof on driving the sprocket wheels.

Mounted within each of l.the compartments a, 5, c, Z of each lmold box is a` false bottom 62 comprising a` rectangular plate the margins of which slidably conform` to the walls of the compartments, and which plate is formed with circular apertures 63 slidably encircling the cylinders 53 to permit vertical movement or the false bottom. This false bottom normally seats on the rods 51, as shown in Figure 7. j

Means are provided for effecting vertical movement of the false bottom 62 which is hereshown as comprising downwardly eirtending` projections 64 and 65 ailixe'd to the ends of the" bottom plate' 62, and which projections are adapted to be engaged by an ejecting mechanism 66, as shown in Figures l, 9, and 10', whereby the projections 64'and 65 with the bottom plate 62 may be moved upwardly. This ejecting Adevice 66 is located at the discharge station H and comprises an endless chain 67 passing around rollers 68 and 69, the upper lead of which yendless chain extends upwardly at an incline beneath the projections 64 and 65, so as to forni inclined planes, up which the projections travel while being .advanced with the mold box conveyor. The chain 67 may be driven from any suitable source of power and is designed to travel in unison with the mold conveyor. `In order to oppose depression of the upper lead of the chain 67, the latter is passed over a supporting ledge 70 which ledge is inclined at one end and has .a horizontally ezttending portion 7 0 at its opposite` end so that the upper lead of the chain 67 will have correspondingly inclined and horizontal.portions. `By this construction the project-ions 64 and 65 may be caused to move upward bythe inclined portion oi the chain 67 and will be maintained in their uppermost position for a distance by the horizontally extendingportion of the chain. By employing chain 67 and driving it at a speed corresponding to the forward movement or the mold boxes no sliding frictional movement is imposed on the lower ends or the projections.

An important feature of this ejecting device' 66 resides in the fact that the false bottoms of the molds will be caused to initially move Aupward in successive order so that the ,work of starting the ejection or" the blocks from the molds will be imposed on one block at a time as will later appear.

Means are provided `to: restoring the false bottoms to theiil normal lowermost positions a'lter the bloc is have been removed therefrom, which is here shown as comprising a pair or downwardly inclined rails 7l and 72, which are positioned to extend in the path or travel or pins 3' and 74 extending outwardly from the lower end portions or the projections 64 und 65, on the false bottoms 62,- in such manner that as the mold boxes are advanced the pins 73 and 7 4 inengaging the underside or Vthe rails 7l and 72 will act to draw the false bottoms downwardly to their normallowermost positions.

Means are provided 'for sprayingl the mold bloc is with oil after the blocks have been removed therefrom and before the wet plastic delivered thereto which means is here shown as comprising a series of pipes 75 which extend horizontally above the mold bor-:es and connect with a suitable source or oil supply under pressure; the pipes 75 being formed with a series or discharge orilices 76 on their under sides adapted to direct sprays of oil downwardly into the mold boxes as the latter pass therebeneath. These pipesare here shown as disposed at a point to deliver the oil to the mold bones immediately after the removal or the blocks thereir-oin,` and at a point in the conveyor G such dis nce from the'lilling` station E that the mold boxes after receiving a bath or oil will. be advanced during time sullicient to permit excess oil todrain from the mold boxes. A drip pan 77 is ar 'anged to catch the oil drained from the mold boxes, trom whence the `oil is delivered to a suitable reservoir, not shown, so that it may be pumped back through the oil distributing pipes.

The operation ot the invention will be understood from the foregoing, it being seen that on deliveringnY a wet plastic composition through the nozzle 30 to the openupper ends of the mold boxes, as shown in Figure 5, the mold boxes will be lilled successively as the mold conveyor advances;` the mold boxes being filled flush with their upper edges by a worlrniaii with the aid of a trowel or similai-tool.` To facilitate this operation, a pair of panels a and b areV mounted to seat on the side flanges -50 of the molds as the latter pass beneath the nozzle 3() as shown in Figure 5 sofas to prevent overflow of the plastic at the sides of the boxes. Thel feed of the plastic is regulated so that such quantity will be discharged as tojust fill the molds, but a volume is fed initially somewhat in excess of that required tov fill a mold so as to give a supply which piles up inthe trough formed between the panels a and b which the workman works back as the molds advance so as to properly fill the molds. The panels ci and Z/ are herel shown as slidably mounted in guideways c and el on the nozzle 29 and arranged in sliding contact with the upper surfaces of the mold boxes. The adjacent mold boxes are arranged with their projecting flanges 50 contacting and thereby obviating any space between the contiguous mold boxes so there will be practically no waste of the plastic by reason of portions thereof being discharged between the advancing mold boxes. Y

rllhe mold boxes being thus filled are carried forward as before described, such length of time as to permit the plastic to set; whereupon, the false bottoms are elevated by the ejector 66 as before stated being elevated siiccessively, one at time in their initial upward movement, as particularly shown in Figure 9. rThis is important in that it minimizes the amount ofpower required to operate the machine, as the plastic in expanding offers considerable resistance to initial movement. As a means for breaking suction in the chambers C of the blocks the latter are moved upward from the cores which would tend to draw/the plastic walls of the openings inwardly -and thereby distort the block, tapered projections e are provided on the upper ends'of the cores which serve to form small vents f in the ends of the chambers C. Nhen the projections 64 and 65 are traversing the horizontal uppermost 'portions of the chain 67, then the false bottoms will be disposed in their uppermost position with the blocks seated thereon as particularly shown in Figure l0, whereupon the blocks may be removed in any suitable manner. This removal may be successfully accomplished by hand. The blocks may be lifted one at a time from the mold conveyor and placed upon the conveyor belt l and aie then carried forward for such a distance and such length of time as to harden and Set, whereupon they are stacked as indicated at J on a wheeled truck 78 and conveyed thereby into a suitable kiln where the blocks are thoroughly dried. f

After the blocks have been lifted from the molds at station H the false bottoms are restoredto theirnormal lowerinost positions by the action of the inclined rails fl- 72 on the pins T3-74, as before described, during fwhich time the interior walls of the molds are given an oil bath as before stated.

As a means for preventing jamming of 'false bottoms iirevent of sticking thereof, ythe rails 7l are pivoted at their upper ends as indicated at y to the standards i and are shown, but may employ such changes and modifications as come within the scope of the appended claims.

I claiml. ln a hollow block molding machine, a series of connected mold boxes, means for advancing said mold boxes continuously, means for feeding a Wet unstable plastic composition to said mold boxes, cores in said mold boxes, means for ejecting molded blocks from said boxes, and means carried by .said cores for breaking suction in the blocks as the latter are ejected.

2. In a machine for molding hollow blocks, a mold box divided into a series of compartments, means for advancing said mold box continuously, .a false bottom in .each ofsaid compartments, and means for elevating said false bottoms operable to initially move saidV false bottoms consecutively as the mold box advances.

8. n a machine for molding hollow blocks, a mold box divided into a series of compartments, means for advancing said mold box continuously, a false bottom in each of said compartments, means for elevatine` said false bottoms operable to initially move said false bottoms consecutively as the` mold box advances, .and means for restoring said false bottoms to their normal lower-l inost positions.

t. ln. a machine of the class described, an endless series of hingedly related mold-boxes, means for imparting continuous motion to the series, means for guiding the series of mold-boxes in a constant plane, means dividing each mold-box into several mold-compartments, an ejector for each compartment, an endless chain bearing an angle inclined relative tothe trend of movement of4 the mold-boxes for engagement with the ej ectors, and means for moving the endless chain in synchronism with the mold-boxes.

5. In a machine of the class described, .an endless series of hingedly related inold-boxes, means for imparting continuous motion to the series, means for guiding the series of mold-boxes in a constant plane, means dividing each' mold-box into several mold-compartments, an ejector for each compartment, an endless chain bearing an angle inclined relative to the trend of movement of the mold-boxes for engagement with the ejectors, means for moving the endless chain in synchronism With the mold-boxes, whereby the combined movements of the mold-boxes and chain automatically operate to eject molded articles from the mold-boxes, and means for restoring the ejectors comprising an element bearing an angle differing from .said chain and fixed in the path of said ejectors.

6. In a machine for forming articles oiA plastic material, comprising an endless track- Way, an endless series of hingedly connected mold-boxes, means for imparting continuous movement to the series of mold-boxes, means for continuously supplying plastic material to the mold-boxes, an article ejector for each mold-box, an endless chain for operating the ejectors arranged at an angle to and located in the path of said ejectors, and means comprising a fixed element disposed at an angle opposite the angle of said chain for restoring the ejectors.

GEORGE A. BUTTRESS. 

